METHOD AND SYSTEM FOR CONFINED LASER DRILLING
A method for drilling a hole in a component is provided. The method includes directing a confined laser beam of the confined laser drill towards a near wall of the component and sensing a characteristic of light directed along a beam axis of the confined laser beam away from the component with a sensor. The method also includes determining one or more operational conditions based on the characteristic of the light sensed with the sensor. The one or more operational conditions includes at least one of a depth of the hole being drilled by the confined laser drill and a material into which the confined laser beam of the confined laser drill is being directed. Such a method may allow for more appropriate control of the confined laser drill.
The present disclosure relates to a method and system for drilling one or more holes in a component a confined laser drill.
BACKGROUND OF THE INVENTIONTurbines are widely used in industrial and commercial operations. A typical commercial steam or gas turbine used to generate electrical power includes alternating stages of stationary and rotating airfoils. For example, stationary vanes may be attached to a stationary component such as a casing that surrounds the turbine, and rotating blades may be attached to a rotor located along an axial centerline of the turbine. A compressed working fluid, such as but not limited to steam, combustion gases, or air, flows through the turbine, and the stationary vanes accelerate and direct the compressed working fluid onto the subsequent stage of rotating blades to impart motion to the rotating blades, thus turning the rotor and performing work.
An efficiency of the turbine generally increases with increased temperatures of the compressed working fluid. However, excessive temperatures within the turbine can reduce the longevity of the airfoils in the turbine and thus increase repairs, maintenance, and outages associated with the turbine. As a result, various designs and methods have been developed to provide cooling to the airfoils. For example, a cooling media can be supplied to a cavity inside the airfoil to convectively and/or conductively remove heat from the airfoil. In particular embodiments, the cooling media flows out of the cavity through cooling passages in the airfoil to provide film cooling over the outer surface of the airfoil.
As temperatures and/or performance standards continue to increase, the materials used for the airfoil become increasingly thin, making reliable manufacture of the airfoil increasingly difficult. For example, certain airfoils are cast from a high alloy metal, and a thermal barrier coating is applied to the outer surface of the airfoil to enhance thermal protection. A water jet can be used to create cooling passages through the thermal barrier coating and outer surface, but the water jet causes portions of the thermal barrier coating to chip off. Alternately, the thermal barrier coating can be applied to the outer surface of the airfoil after the cooling passages have been created by an electron discharge machine (EDM), but this requires additional processing to remove any thermal barrier coating covering the newly formed cooling passages. Moreover, this process of re-opening the cooling holes after the coating process becomes increasingly difficult and requires more labor hours and skill when the sizes of the cooling holes decrease and the number of cooling holes increase.
A laser drill utilizing a focused laser beam can be used to create the cooling passages through the airfoil with a reduced risk of chipping the thermal barrier coating. The laser drill, however, requires precise control due to the presence of the cavity within the airfoil. Once the laser drill breaks through a near wall of the airfoil, continued operation of the laser drill by conventional methods can result in damage to an opposite side of the cavity, potentially resulting in a damaged airfoil that must be refurbished or discarded.
Accordingly, a method and system for determining a breakthrough of a laser drill when drilling a hole in a component of a gas turbine would be beneficial. More particularly, a method and system for determining a breakthrough of a laser drill when drilling a hole in a component of a gas turbine based on one or more operating conditions determined during such a drilling process would be particularly useful.
BRIEF DESCRIPTION OF THE INVENTIONAspects and advantages of the invention are set forth below in the following description, or may be obvious from the description, or may be learned through practice of the invention.
In one exemplary aspect of the present disclosure, a method for drilling a hole in a near wall of a component is provided. The method includes directing a confined laser beam of a confined laser drill towards the near wall of the component to drill the hole in the near wall of the component. The confined laser beam defines a beam axis and the near wall is positioned adjacent to a cavity defined in the component. The method also includes sensing a characteristic of light directed along the beam axis away from the component with a sensor. The method also includes determining one or more operational conditions based on the characteristic of light sensed with the sensor. The one or more operational conditions includes at least one of a depth of the hole being drilled by the confined laser drill and a material into which the confined laser beam of the confined laser drill is being directed.
In one exemplary embodiment of the present disclosure, a system is provided for drilling a hole in a near wall of a component. The system includes a confined laser drill utilizing a confined laser beam defining a beam axis. The confined laser drill is configured to drill the hole through the near wall of the component, and the near wall is positioned adjacent to a cavity defined by the component. The system also includes a sensor positioned to sense a characteristic of light directed along the beam axis away from the near wall of the component. The system also includes a controller operably connected to the sensor. The controller is configured to determine one or more operational conditions based on the characteristic of light sensed with the sensor. The one or more operational conditions includes at least one of a depth of the hole being drilled and a material into which the confined laser beam of the laser drill is being directed.
These and other features, aspects and advantages of the present disclosure will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the disclosure and, together with the description, serve to explain the principles of the disclosure.
A full and enabling disclosure of the present disclosure, including the best mode thereof to one skilled in the art, is set forth more particularly in the remainder of the specification, including reference to the accompanying figures, in which:
Reference now will be made in detail to embodiments of the disclosure, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the disclosure, not limitation of the disclosure. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present disclosure without departing from the scope or spirit of the disclosure. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present disclosure covers such modifications and variations as come within the scope of the appended claims and their equivalents. Although exemplary embodiments of the present disclosure will be described generally in the context of manufacturing an airfoil 38 for a turbomachine for purposes of illustration, one of ordinary skill in the art will readily appreciate that embodiments of the present disclosure may be applied to other articles of manufacture and are not limited to a system or method for manufacturing an airfoil 38 for a turbomachine unless specifically recited in the claims. For example, in other exemplary embodiments, aspects of the present disclosure may be used to manufacture an airfoil 38 for use in the aviation context or to manufacture other components of a gas turbine.
As used herein, the terms “first”, “second”, and “third” may be used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components. Similarly, the terms “near” and “far” may be used to denote relative position of an article or component and are not intended to signify any function or design of said article or component.
Referring now to the drawings,
As shown in
One of ordinary skill in the art will readily appreciate from the teachings herein that the number and/or location of the cooling passages 52 may vary according to particular embodiments, as may the design of the cavity 46 and the design of the cooling passages 52. Accordingly, the present disclosure is not limited to any particular number or location of cooling passages 52 or cavity 46 design unless specifically recited in the claims.
In certain exemplary embodiments, a thermal barrier coating 36 may be applied over at least a portion of an outer surface 34 of a metal portion 40 of the airfoil 38 (see
Referring now to
Exemplary system 60 generally includes a confined laser drill 62 configured to direct a confined laser beam 64 towards a near wall 66 of the airfoil 38 to drill a hole 52 in the near wall 66 of the airfoil 38. The confined laser beam 64 defines a beam axis A and the near wall 66 is positioned adjacent to the cavity 46. More particularly, various embodiments of the confined laser drill 62 may generally include a laser mechanism 68, a collimator 70, and a controller 72. The laser mechanism 68 may include any device capable of generating a laser beam 74. By way of example only, in certain exemplary embodiments, laser mechanism 68 may be a diode pumped Nd:YAG laser capable of producing a laser beam at a pulse frequency of approximately 10-50 kHz, a wavelength of approximately one micrometer, or if utilizing second harmonic generation (“SHG”) between 500-550 nanometers, and an average power of approximately 10-200 W. However, in other embodiments, any other suitable laser mechanism 68 may be utilized.
In the particular embodiment shown in
As shown in the enlarged view in
As stated, the confined laser beam 64 may be utilized by confined laser drill 62 to, e.g., drill one or more cooling passages 52 through airfoil 38. More particularly, confined laser beam 64 may ablate outer surface 34 of the airfoil 38, eventually creating the desired cooling passage 52 through the airfoil 38. Notably,
With continued reference to
As shown most clearly in
The exemplary system 60 of
Referring still to the exemplary system 60 of
Referring now to
The method (120) generally includes at (122) directing a confined laser beam of a confined laser drill towards a near wall of the airfoil to drill the hole in the near wall of the airfoil. The confined laser beam defines a beam axis and the near wall is positioned adjacent to a cavity defined in the airfoil. The method (120) additionally includes at (124) sensing a characteristic of light directed along the beam axis away from the airfoil with a sensor. The light directed along the beam axis away from the airfoil may, in certain aspects, refer to the light reflected from the near wall of the airfoil. In certain exemplary aspects, sensing a characteristic of light at (124) may include sensing at least one of an intensity of light, one or more wavelengths of light, a shape of a light pulse in time, and a shape of a light pulse in frequency. Additionally, the sensor may be offset from the beam axis, such that sensing a characteristic of light at (124) may further include redirecting at least a portion of the light directed along the beam axis away from the airfoil to the sensor with a lens.
Referring still to
For example, in certain exemplary aspects, sensing a characteristic of light at (124) may include sensing an intensity of light. For illustration, reference will now also be made to
Notably, if all of the light directed at the airfoil was reflected without being absorbed or otherwise altered, the reflected pulse rate and reflected pulse width would accurately reflect an actual pulse rate and an actual pulse width at which the confined laser drill and confined laser beam is operating. However, during drilling operations, an amount of light absorption by the airfoil may vary based on, e.g., a depth of the hole, an aspect ratio of the hole (which, as used herein, refers to a ratio of a hole diameter verses a hole length), and/or the material into which the confined laser beam is being directed (i.e., the material being drilled through). Accordingly, during drilling operations, the exemplary method (120) may include comparing the values of one or both of the reflected pulse rate and reflected pulse width determined at (126) to known operational conditions of the confined laser drill (e.g., the actual pulse rate and/or actual pulse width of the confined laser drill). Such a comparison may reveal an error value. The error value may then be compared to a lookup table relating such error values to hole depths—accounting for the particular material being drilled into, the hole diameter, the hole geometry, and any other relevant factors—to determine a depth of the hole being drilled by the confined laser drill in the near wall of the airfoil. The lookup table values may be determined experimentally.
It should be appreciated, however, that in other exemplary aspects of the present disclosure, the exemplary method may additionally or alternatively sense at (124) other characteristics of light directed along the beam axis and determine at (126) other operational conditions. For example, referring still to
In other exemplary aspects, however, the method (120) may include sensing light at a plurality of wavelengths. For example, light directed along the beam axis when drilling through both the thermal barrier coating and the metal portion may additionally define a fourth wavelength 163 and light directed along the beam axis when drilling through the metal portion and when at least partially broken through the near wall of the airfoil may additionally define a fifth wavelength 165. Moreover, in other exemplary embodiments, the light may define any other distinct pattern of wavelengths based on a variety of factors, including the material(s) into which the confined laser drill is directed, the depth of the hole being drilled, an aspect ratio of the hole being drilled, etc. Accordingly, the method (120) may include utilizing a fuzzy logic methodology to determine the one or more operational conditions at (126), including, for example, the material into which the confined laser beam is being directed.
Moreover, in still other exemplary aspects of the present disclosure, the exemplary method may additionally or alternatively sense at (124) still other characteristics of light directed along the beam axis and determine at (126) other operational conditions. For example, referring still to
Referring still to
The method of
Notably, although a portion of the confined laser beam may have broken through the near wall the airfoil, the hole may not be complete. More particularly, the hole may not yet define a desired geometry along an entire length of the hole. Accordingly, for the exemplary aspect depicted, the exemplary method (120) of
The exemplary method of
Referring now to
The exemplary system 60 depicted in
However, for the embodiment of
For the embodiment depicted, the sensor 98 is positioned outside the airfoil 38, such that the sensor defines a line of sight 100 to the beam axis A of the confined laser beam 64. As used herein, the term “line of sight” refers to a straight line from one position to another position free from any structural obstacles. Accordingly, the sensor 98 may be positioned anywhere outside the cavity 46 of the airfoil 38 that allows the sensor 98 to define the line of sight 100 to the beam axis A within the cavity 46. For example, in the embodiment depicted, the sensor 98 is positioned adjacent to the opening 54 (shown schematically) of the airfoil 38 and directed through the opening 54 of the airfoil 38 into the cavity 46 of the airfoil 38.
Typically, it is difficult to sense light from a laser beam unless such laser beam is contacting a surface (such that light is reflected and/or redirected) or unless the sensor is positioned in alignment with an axis of the laser beam. For the embodiment depicted, the backstrike protection mechanism 82 is configured to disrupt the confined laser beam 64 within the cavity 46 of the airfoil 38 after the confined laser beam 64 has broken through the near wall 66 of the airfoil 38. More particularly, as previously stated, the confined laser beam 64 includes a liquid column 80 and a laser beam 74 within the liquid column 80. Referring particularly to
In certain embodiments, the sensor 98 may be positioned outside the cavity 46 and directed into the cavity 46 such that the sensor 98 is configured to detect light from within the cavity 46 of the airfoil 38 at a plurality of locations. More particularly, the sensor 98 may be positioned outside the cavity 46 and directed into cavity 46 such that the sensor defines a line of sight 100 with the beam axis A of the confined laser beam 64 at a first hole location as well as with a second beam axis A′ of the confined laser beam 64 at a second hole location (see
Referring now to
As shown, the exemplary method (200) includes at (202) directing a confined laser beam of a confined laser drill towards a first hole position on a near wall of the airfoil. The near wall may be positioned adjacent to a cavity defined in the airfoil. The method also includes at (204) sensing a characteristic of light within the cavity defined by the airfoil using a sensor positioned outside the cavity defined by the airfoil. In certain exemplary aspects, the sensor may be positioned adjacent to an opening defined by the airfoil and directed through the opening into the cavity. The sensor may therefore be positioned at a location that does not intersect with a beam axis defined by the confined laser beam, but defines a line of sight to the beam axis defined by the confined laser beam within the cavity of the airfoil.
The method (200) further includes at (206) activating a backstrike protection mechanism. Activating the back straight protection mechanism at (206) may be, for example, in response to operating the confined laser drill for a predetermined amount of time. Additionally, activating the backstrike protection mechanism at (206) may include flowing a gas through the cavity of the airfoil such that the gas intersects the beam axis within the cavity of the airfoil. Accordingly, once the confined laser beam of the confined laser drill breaks through the near wall of the airfoil, the method (200) further includes at (208) disrupting the confined laser beam within the cavity of the airfoil with the backstrike protection mechanism. More particularly, disrupting the confined laser beam within the cavity at (208) may include disrupting a liquid column of the confined laser beam such that a liquid from the liquid column intersects the beam axis and a laser beam of the confined laser beam. The liquid intersecting the beam axis may be at least partially illuminated by the laser beam of the confined laser beam within the cavity of the airfoil.
The exemplary method of
Subsequent to determining the first breakthrough of the confined laser beam at (210), the exemplary method may include shutting off the confined laser drill and repositioning the confined laser drill to drill a second cooling hole. Additionally, the exemplary method includes at (212) directing the confined laser beam of the confined laser drill towards a second hole position on the near wall of the airfoil. The method (200) further includes at (214) sensing a characteristic of light within the cavity defined by the airfoil using the sensor subsequent to directing the confined laser beam towards the second hole position at (212). Further, the method (200) of
The exemplary method of
Referring now to
The exemplary system 60 depicted in
However, for the embodiment of
By contrast, after the confined laser drill 62 has broken through the near wall 66 of the airfoil 38 (
For the embodiment of
It should be appreciated, however, that in other exemplary embodiments, any other suitable sensor 102 may be provided. For example, in other exemplary embodiments the sensor 102 may be a motion sensor, a humidity sensor, or any other suitable sensor. When the sensor 102 is a motion sensor, for example, the sensor may determine whether or not a plume 106 of liquid back spray is present in the backsplash area 104. A breakthrough may be determined when the plume 106 of liquid back spray is no longer present in the backsplash area 104.
Referring now to
As stated, the confined laser drill 62 defines a backsplash area 104 where liquid from the confined laser beam 64 sprays prior to the confined laser beam 64 breaking through the near wall 66 of the airfoil 38. For the embodiment depicted, the light source 108 is positioned outside the airfoil 38 and configured to direct light through at least a portion of the backsplash area 104. Additionally, for the embodiment depicted, the light source 108 is positioned directly opposite the backsplash area 104 from the sensor 102, the light source 108 is directed at the sensor 102, and the sensor 102 is directed at the light source 108. However, in other exemplary embodiments the light source 108 and sensor 102 may be offset from one another relative to the backsplash area 104, the light source 108 may not be directed at the sensor 102, and/or the sensor 102 may not be directed at the light source 108.
As stated, for the embodiment depicted the sensor 102 is directed at the light source 108 and the light source 108 is directed at the sensor 102, such that an axis 110 of the light source intersects with the sensor 102. In such an embodiment, sensing an intensity of light above a predetermined threshold may indicate a decreased amount of liquid from the confined laser beam 64 is present outside the airfoil 38 and thus that the confined laser beam 64 has broken through the near wall 66 of the airfoil 38. More particularly, when liquid is present in the backsplash area 104, such liquid may disrupt or redirect light from the light source 108 such that an intensity of light sensed by the sensor 102 is relatively low. By contrast, when no liquid, or a minimal amount of liquid, is present in the backsplash area 104, the amount of disruptions are limited between the light source 108 and the sensor 102, such that a relatively high intensity of light may be sensed by the sensor 102. Accordingly, with such a configuration, sensing a relatively high intensity of light may indicate the confined laser beam 64 has broken through the near wall 66 of the airfoil 38.
In other exemplary embodiments, however, such as when the light source 108 is not directed at the sensor 102 and the sensor 102 is not directed at the light source 108, sensing an intensity of light below a predetermined threshold indicates a decreased amount of liquid from the confined laser beam 64 is present outside the airfoil 38. More particularly, when the light source 108 is not directed at the sensor 102 and the sensor 102 is not directed to light source 108, the sensor 102 may sense an increased intensity of light when light from the light source is redirected and reflected by liquid in the backsplash area 104. However, when no liquid, or a minimal amount of liquid, is present in the backsplash area 104, light from the light source is not redirected or reflected by such liquid and the sensor 102 may therefore sense a relatively low intensity of light. Accordingly, in such an exemplary embodiment, sensing an intensity of light below a predetermined threshold may indicate that the confined laser beam 64 has broken through the near wall 66 of the airfoil 38.
Referring now to
As shown, the exemplary method (300) includes at (302) positioning a confined laser drill within a predetermined distance of a near wall of an airfoil of a gas turbine. The exemplary method (300) also includes at (304) directing a confined laser beam of the confined laser drill towards an outside surface of the near wall of the airfoil. The confined laser beam includes a liquid column formed of a liquid and a laser beam within the liquid column. The exemplary method (300) also includes at (306) sensing an amount of liquid present outside the near wall of the airfoil from the confined laser beam with a sensor. Moreover, the exemplary method (300) includes at (308) determining a breakthrough of the confined laser beam of the confined laser drill through the near wall the airfoil of the gas turbine based on the amount of liquid sensed outside the near wall of the airfoil at (306).
In certain exemplary aspects, wherein the sensor includes a camera, sensing an amount of liquid present outside the near wall the airfoil at (306) may include comparing one or more images received from the camera to one or more stored images to determine the amount of liquid present. Any suitable pattern recognition software may be utilized to provide such functionality.
Utilizing a Plurality of SensorsReferring now to
The exemplary system 60 of
The exemplary system 60 of
For the embodiment depicted in
Moreover, for the embodiment of
As will be explained in greater detail below with reference to
It should be appreciated, however, that in other exemplary embodiments of the present disclosure, the first sensor 110 and the second sensor 112 may be positioned at any other suitable location. For example, in other exemplary embodiments, first sensor 110 and the second sensor 112 may each be positioned to sense light directed along the beam axis A away from the near wall 66 of the airfoil 38. Alternatively, the first sensor 110 and the second sensor 112 may each be positioned such that each respective sensor 110, 112 defines a line of sight to the hole in the near wall 66 of the airfoil 38 nonparallel to the beam axis A. Alternatively, one or both of the first sensor 110 and the second sensor 112 may be positioned outside the cavity 46 of the airfoil 38 and directed into the cavity 46 of the airfoil 38 (similar to, e.g., sensor 98 discussed above with reference to
Referring now to
The exemplary method (400) of
The exemplary method (400) also includes at (406) sensing a second characteristic of light from the hole in the airfoil with a second sensor. The second characteristic of light sensed with the second sensor at (406) is different from the first characteristic of light sensed with the first sensor at (404). For example, in certain exemplary aspects, the second characteristic of light may be an intensity of light at a second wavelength. The second wavelength may be indicative of the confined laser beam hitting a second layer of the near wall of the airfoil. For example sensing light at the second wavelength may be indicative of the confined laser beam hitting a metal portion of the near wall of airfoil.
The method further includes at (408) determining a hole progress based on the first characteristic of light sensed at (404) and the second characteristic of light sensed at (406). In certain exemplary aspects, determining the hole progress at (408) based on the first characteristic of light sensed at (404) and the second characteristic of light sensed at (406) may include comparing the intensity of light sensed at the first wavelength to an intensity of light sensed at the second wavelength. For example, a ratio of the intensity of light sensed at the first wavelength to the intensity of light sensed at the second wavelength may be indicative of a progress of the hole through the first layer of the near wall of the airfoil.
In certain exemplary aspects, determining the hole progress at (408) based on the first characteristic of light sensed at (404) and the second characteristic of light sensed at (406) may further include determining the hole is at least a predetermined amount through the first layer of the near wall of the airfoil. For example, the exemplary method may include determining the hole is at least about ninety percent through the first layer of the near wall the airfoil, such as at least about ninety-five percent through the first layer of the near wall of the airfoil, such as at least about ninety-eight percent through the first layer of the near wall of the airfoil.
Additionally, depending on certain factors, such as the type of material the thermal barrier coating is made of, it may be desirable to drill through the thermal barrier coating of the near wall of the airfoil at a lower power than through the underlying metal portion of the airfoil. Accordingly, in response to determining the hole progress at (408), for example, in response to determining the hole is at least a predetermined amount through the first layer of the near wall the airfoil, the method (400) may further include at (410) adjusting one or more operating parameters of the confined laser drill. For example, the method (400) may include increasing a power, increasing a pulse rate, and/or increasing a pulse width of the confined laser drill.
Is be appreciated, however, that in other exemplary aspects, the first characteristic of light and second characteristic of light may each be any other suitable characteristic of light. For example, in other exemplary aspects, the first sensor may be a suitable optical sensor and the first characteristic of light may be an intensity of light. Such an exemplary aspect may further include determining one or both of a reflected pulse width of the confined laser drill and a reflected pulse frequency of the confined laser drill. Similar to as discussed in greater detail above with reference to
In such an exemplary aspect, in response to determining the depth of the hole and determining the material into which the confined laser beam is being directed, the exemplary method (400) of
In any of the above exemplary aspects, it should be appreciated that determining the hole progress at (408) based on the first characteristic of light sensed at (404) and the second characteristic of light sensed at (406) may include using any suitable control methodology. For example, determining the hole progress at (408) may include utilizing lookup tables taking into account certain factors. These lookup tables may be determined experimentally. Additionally, or alternatively, determining the hole progress at (408) may include utilizing a fuzzy logic control methodology to analyze the sensed first and second characteristics of light sensed at (404) and (406), respectively.
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other and examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.
Claims
1. A method for drilling a hole in a near wall of a component, the method comprising:
- directing a confined laser beam of a confined laser drill towards the near wall of the component to drill the hole in the near wall of the component, the confined laser beam defining a beam axis and the near wall positioned adjacent to a cavity defined in the component;
- sensing a characteristic of light directed along the beam axis away from the component with a sensor; and
- determining one or more operational conditions based on the characteristic of light sensed with the sensor, the one or more operational conditions including at least one of a depth of the hole being drilled by the confined laser drill and a material into which the confined laser beam of the confined laser drill is being directed.
2. The method of claim 1, wherein the component is an airfoil of a turbine.
3. The method of claim 1, wherein the sensor is offset from the beam axis, and wherein sensing a characteristic of light directed along the beam axis away from the component with the sensor comprises redirecting at least a portion of the light directed along the beam axis away from the component to the sensor with a lens.
4. The method of claim 3, wherein the lens is positioned in the beam axis at approximately a forty-five degree angle with the beam axis, and wherein the lens includes a coating on a first side for redirecting at least a portion of the light traveling along the beam axis away from the component to the sensor.
5. The method of claim 1, wherein sensing a characteristic of light directed along the beam axis away from the component with the sensor comprises sensing an intensity of light directed along the beam axis away from the component with the sensor, and wherein determining one or more operational conditions based on the characteristic of light sensed with the sensor comprises determining one or both of a reflected pulse rate of the confined laser drill and a reflected pulse width of the confined laser drill.
6. The method of claim 5, wherein determining one or more operational conditions based on the characteristic of light sensed with the sensor further comprises determining a depth of the hole being drilled based on one or both of the reflected pulse rate and the reflected pulse width.
7. The method of claim 1, wherein sensing a characteristic of light directed along the beam axis away from the component with the sensor comprises sensing a one or more wavelengths of the light directed along the beam axis away from the component with the sensor, and wherein determining one or more operational conditions based on the characteristic of light sensed with the sensor comprises comparing the sensed one or more wavelengths of the light to predetermined values.
8. The method of claim 7, wherein determining one or more operational conditions based on the characteristic of light sensed with the sensor further comprises determining a material into which the confined laser beam of the confined laser drill is being directed based on the comparison of the sensed one or more wavelengths to predetermined values.
9. The method of claim 1, further comprising
- changing an operational parameter of the confined laser drill in response to determining one or more operational conditions.
10. The method of claim 1, further comprising
- determining an indicated breakthrough of the confined laser beam of the confined laser drill through the near wall of the component based on the characteristic of light sensed along the beam axis with the sensor.
11. The method of claim 10, further comprising
- determining a breakthrough of the confined laser beam of the confined laser drill through the near wall of the component based on one or both of the determined one or more operational conditions and the determined indicated breakthrough.
12. The method of claim 11, further comprising
- continuing to direct the confined laser beam of the confined laser drill towards the near wall of the component subsequent to determining a breakthrough of the confined laser beam of the confined laser drill through the near wall of the component; and
- determining a completion of the hole in the near wall of the component based on the characteristic of light sensed along the beam axis with the sensor.
13. The method of claim 1, wherein sensing a characteristic of light directed along the beam axis away from the component with a sensor comprises sensing an intensity of light directed along the beam axis away from the component with a sensor, and wherein determining one or more operational conditions based on the characteristic of light sensed with the sensor comprises determining a noise level in the intensity of light directed along the beam axis away from the component.
14. The method of claim 13, wherein determining one or more operational conditions based on the characteristic of light sensed with the sensor further comprises determining a depth of the hole being drilled based on the determined noise level in the intensity of light directed along the beam axis away from the component.
15. A system for drilling a hole in a near wall of a component, the system comprising:
- a confined laser drill utilizing a confined laser beam defining a beam axis, the confined laser drill configured to drill the hole through the near wall of the component, the near wall positioned adjacent to a cavity defined by the component;
- a sensor positioned to sense a characteristic of light directed along the beam axis away from the near wall of the component; and
- a controller operably connected to the sensor, the controller configured to determine one or more operational conditions based on the characteristic of light sensed with the sensor, the one or more operational conditions including at least one of a depth of the hole being drilled and a material into which the confined laser beam of the laser drill is being directed.
16. The system of claim 15, wherein the sensor is an oscilloscope.
17. The system of claim 15, wherein the controller is further configured to determine an indicated breakthrough of the confined laser beam of the confined laser drill through the near wall of the component based on the characteristic of light sensed with the sensor.
18. The system of claim 15, wherein the sensor is configured to sense an intensity of the light directed along the beam axis away from the near wall of the component.
19. The system of claim 18, wherein the controller is further configured to determine one or both of a reflected pulse rate of the confined laser drill and a reflected pulse width of the confined laser drill, and wherein the one or more operational conditions includes a depth of the hole being drilled.
20. The system of claim 15, wherein the sensor is configured to sense one or more wavelengths of the light directed along the beam axis away from the near wall of the component.
Type: Application
Filed: Jan 8, 2015
Publication Date: Jul 14, 2016
Patent Grant number: 10589385
Inventors: Shamgar Elijah McDowell (Simpsonville, SC), Zhaoli Hu (Greer, SC), Abe Denis Darling (Laurens, SC), Douglas Anthony Serieno (Simpsonville, SC)
Application Number: 14/592,217